Chute Design in the Mining Industry

Infographic showing Hamilton By Design’s engineering workflow, including millimetre-accurate LiDAR reality capture, material-flow simulation, optimised chute designs, and safer, more efficient production outcomes. Two workers in PPE highlight reliable design and longer liner life, with icons representing time, cost and quality benefits.

Getting Coal, Hard Rock, and ROM Material Flow Right

Chute design is one of the most critical yet challenging aspects of mining and mineral processing. Whether you are handling coal, hard rock ore, or raw ROM material, chutes and transfer stations are the unsung workhorses of every operation. When designed well, they guide material smoothly, minimise wear, and keep conveyors running. When designed poorly, they cause blockages, spillage, excessive dust, and expensive downtime.

Modern chute design has moved far beyond rules of thumb and back-of-the-envelope sketches. Today, successful projects rely on accurate as-built data, particle trajectory analysis, and advanced Discrete Element Method (DEM) simulation to predict, visualise, and optimise material flow before steel is cut. In this article, we explore why these tools have become essential, how they work together, and where software can — and cannot — replace engineering judgement.

Illustration showing common problems with poorly designed material-handling chutes. A chute discharges material onto a conveyor while issues are highlighted around it: unpredictable material flow, material spillage, maintenance challenges, high wear, blockages, and dust and noise. Warning icons for downtime and cost appear on the conveyor, and workers are shown dealing with the resulting hazards and maintenance tasks.

The Challenge of Chute Design

Coal and hard rock have very different flow behaviours. Coal tends to be softer, generate more dust, and be prone to degradation, while hard rock is more abrasive and can damage chutes if impact angles are not controlled. ROM material adds another level of complexity — oversize lumps, fines, and moisture variation can cause hang-ups or uneven flow.

Chute design must balance several competing objectives:

Control the trajectory of incoming material to reduce impact and wear
Prevent blockages by maintaining flowability, even with wet or sticky ore
Manage dust and noise to meet environmental and workplace health requirements
Fit within existing plant space with minimal modification to conveyors and structures
Be maintainable — liners must be accessible and replaceable without excessive downtime

Meeting all these goals without accurate data and simulation is like trying to design in the dark.

Illustrated graphic showing a tripod-mounted 3D laser scanner capturing millimetre-accurate as-built data in an industrial plant with conveyors and walkways. Speech bubbles highlight issues such as “Outdated drawings don’t tell the full story” and “Modifications rarely get documented.” The scan data is shown being visualised on a laptop, with notes describing full coverage of conveyors, walkways, and services. Benefits listed along the bottom include faster data collection, fewer site revisits, safer shutdowns, accurate starting point for design simulation, and safer outcomes that ensure designs fit first time.

Capturing the Truth with 3D Scanning

The first step in any successful chute project is to understand the as-built environment. In many operations, drawings are outdated, modifications have been made over the years, and the real plant geometry may differ from what is on paper. Manual measurement is slow, risky, and often incomplete.

This is where 3D laser scanning changes the game. Using tripod-mounted or mobile LiDAR scanners, engineers can capture the entire transfer station, conveyors, surrounding steelwork, and services in a matter of hours. The result is a dense point cloud with millimetre accuracy that reflects the true state of the plant.

From here, the point cloud is cleaned and converted into a 3D model. This ensures the new chute design will not clash with existing structures, and that all clearances are known. It also allows maintenance teams to plan safe access for liner change-outs and other work, as the scanned model can be navigated virtually to check reach and access envelopes.

Understanding Particle Trajectory

Once the physical environment is known, the next challenge is to understand the particle trajectory — the path that material takes as it leaves the head pulley or previous transfer point.

Trajectory depends on belt speed, material characteristics, and discharge angle. For coal, fine particles may spread wider than the coarse fraction, while for ROM ore, large lumps may follow a ballistic path that needs to be controlled to prevent impact damage.

Accurately modelling trajectory ensures that the material enters the chute in the right location and direction. This minimises impact forces, reducing wear on liners and avoiding the “splash” that creates spillage and dust. It also prevents the material from hitting obstructions or dead zones that could lead to build-up and blockages.

Modern software can plot the trajectory curve for different loading conditions, providing a starting point for chute geometry. This is a critical step — if the trajectory is wrong, the chute design will be fighting against the natural path of the material.

The Power of DEM Simulation

While trajectory gives a first approximation, real-world flow is far more complex. This is where Discrete Element Method (DEM) simulation comes into play. DEM models represent bulk material as thousands (or millions) of individual particles, each following the laws of motion and interacting with one another.

When a DEM simulation is run on a chute design:

You can visualise material flow in 3D, watching how particles accelerate, collide, and settle
Impact zones become clear, showing where liners will wear fastest
Areas of turbulence, dust generation, or segregation are identified
Build-up points and potential blockages are predicted

This allows engineers to experiment with chute geometry before fabrication. Angles can be changed, ledges removed, and flow-aiding features like hood and spoon profiles or rock-boxes optimised to achieve smooth, controlled flow.

For coal, DEM can help ensure material lands gently on the receiving belt, reducing degradation and dust. For hard rock, it can ensure that the energy of impact is directed onto replaceable wear liners rather than structural plate. For ROM ore, it can help prevent oversize lumps from wedging in critical locations.

Illustration of an optimised chute design showing material flow represented by green particles, with check marks and gear icons indicating improved efficiency and engineered performance.

🖥 Strengths and Limitations of Software

Modern DEM packages are powerful, but they are not magic. Software such as EDEM, Rocky DEM, or Altair’s tools can simulate a wide range of materials and geometries, but they rely on good input data and skilled interpretation.

Key strengths include:

Ability to model complex, 3D geometries and particle interactions
High visualisation power for communicating designs to stakeholders
Capability to run multiple scenarios (different feed rates, moisture contents, ore types) quickly

However, there are limitations:

Material calibration is critical. If the particle shape, friction, and cohesion parameters are wrong, the results will not match reality.
Computational cost can be high — detailed simulations of large chutes with millions of particles may take hours or days to run.
Engineering judgement is still needed. Software will not tell you the “best” design — it will only show how a proposed design behaves under given conditions.

That’s why DEM is best used as part of a holistic workflow that includes field data, trajectory analysis, and experienced design review.

From Model to Real-World Results

When the simulation results are validated and optimised, the design can be finalised. The point cloud model ensures the chute will fit in the available space, and the DEM results give confidence that it will perform as intended.

This means fabrication can proceed with fewer changes and less risk. During shutdown, installation goes smoothly, because clashes have already been resolved in the digital model. Once commissioned, the chute delivers predictable flow, less spillage, and longer liner life.

Why It Matters More Than Ever

Today’s mining operations face tighter production schedules, stricter environmental compliance, and increasing cost pressures. Downtime is expensive, and the margin for error is shrinking.

By combining 3D scanning, trajectory modelling, and DEM simulation, operations can move from reactive problem-solving to proactive improvement. Instead of waiting for blockages or failures, they can design out the problems before they occur, saving both time and money.

Partnering for Success

At Hamilton by Design, we specialise in turning raw site data into actionable insights. Our team uses advanced 3D scanning to capture your transfer stations with precision, builds accurate point clouds and CAD models, and runs calibrated DEM simulations to ensure your new chute design performs from day one.

Whether you’re working with coal, hard rock, or ROM ore, we help you deliver designs that fit first time, reduce maintenance headaches, and keep production running.

Contact us today to see how our integrated scanning and simulation workflow can make your next chute project safer, faster, and more reliable.

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9 September 202531 May 2026

Chute Design at Hamilton By Design

At Hamilton by Design, we see ourselves as more than engineers — we are problem-solvers who bring both science and experience to the table. Every bulk material transfer is unique, and each one carries its own challenges. By combining the principles of particle physics with decades of hands-on site experience, we design chutes and transfer points that perform in the real world, not just on a computer screen.

We are a small, specialised company, not a large corporate machine. That means you deal directly with the people who understand your operation, your materials, and your challenges. We take pride in our ability to stand on-site, watch the flow of material, and recognise behaviours that only years of experience can teach. This gives us the clarity to engineer practical solutions that keep your plant running reliably.

For us, your success is our success. We measure our achievement not by the number of projects we complete, but by the value we add to your operation — less dust, less wear, fewer stoppages, more tonnes moved.

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9 September 202531 May 2026

Chute Design At Hamilton By Design

Coal plant shutdown engineering using a 3D laser scanner to capture conveyor and transfer chute infrastructure.

At Hamilton by Design, we believe that every bulk material transfer is an opportunity for improvement. What appears to be a simple flow of rock, coal, grain, or powder is, in reality, a particle physics problem waiting to be solved. By approaching these challenges with precision, creativity, and hands-on knowledge, we deliver chute designs that do more than move material — they protect assets, enhance performance, and improve the bottom line.

Infographic showing Hamilton By Design in a central blue circle with the text ‘Practical experience. Particle physics. Smarter transfer points.’ Surrounding circles highlight benefits: reduced dust, extended life, efficiency gains, quality preservation, and tailored solutions.

We are a small, specialised company with a wealth of on-site experience. Our engineers have spent years in the field, watching, listening, and learning how different materials behave under real conditions. This raw experience gives us a unique advantage: we can see and understand particle flow first-hand, not just through numbers on a screen. While many large organisations rely solely on computer models, we combine advanced simulation with practical insight, ensuring solutions that work not only in theory but also in practice.

Our team thrives on solving the complex problems others overlook:

Redirecting hard rock at speed without spillage or damage.
Handling sticky coal without blockages or hang-ups.
Containing fine powders without dust plumes or health risks.
Transferring fragile grains without breakage or product loss.
Extending chute, liner, and belt life with robust material-on-material flow designs.

We approach every challenge with the mindset that your success is our success. When your plant runs reliably, safely, and efficiently, we succeed alongside you. That’s why we design transfer points that:

Absorb and dissipate energy from high-impact lumps.
Control dust and minimise degradation for cleaner, safer operations.
Extend equipment life by reducing wear and maintenance.
Adapt to variability in feed size, flow, and moisture.
Boost throughput and availability by minimising stoppages.

In a world where margins are tight and environmental responsibility is critical, Hamilton by Design offers a personal, client-focused approach that puts performance and partnership at the centre. We are not a large organisation pushing generic solutions — we are a dedicated team that listens, observes, and engineers smarter outcomes, one particle physics problem at a time.

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5 September 202531 May 2026

Designing for Developing Hazards: Lessons from the Derrimut Crane Collapse

Designing for Developing Hazards

Crane accidents are among the most visible reminders of the risks inherent in construction. The collapse of a crane at a data centre site in Derrimut, Melbourne, brought attention once again to the vulnerability of temporary lifting structures. While formal investigations are still underway, and no conclusions should be drawn prematurely, the event provides a valuable opportunity for reflection within the engineering community.

This article considers the collapse not as an isolated failure but as a case study in hazard identification. In particular, it highlights how mechanical engineers must adapt from a static, design-phase view of risk to a dynamic, real-time approach to hazard monitoring. Wind, soil stability, and load conditions are well-known hazards. But with modern tools — including LiDAR scanning for obstacle detection — engineers can move toward a future where developing hazards are continuously tracked, anticipated, and controlled.

From Hazard Identification to Live Hazard Monitoring

Hazard identification has traditionally been a design-phase process: engineers anticipate risks, apply safety factors, and create conservative margins. This remains essential. Yet the Derrimut collapse illustrates the limits of a static model in a dynamic environment.

Cranes are exposed to evolving hazards:

Wind gusts that change minute by minute.
Soil stability that shifts with rainfall, excavation, or groundwater.
Obstacles such as power lines or nearby structures, which can create cascading risks if struck.
Load dynamics, including swinging or sudden movement.

What is needed is a transition from hazard identification to hazard monitoring: a continuous loop where design assumptions are validated against real-time data, and where developing risks are detected before they become failures.

Wind Hazards: Predicting the Unpredictable

Wind is a leading cause of crane collapses. Engineers know the mathematics: pressure rises with the square of velocity. A 50 km/h gust exerts twice the force of a 35 km/h breeze.

Most cranes today are fitted with anemometers and alarms, but these are often basic: a single reading at a single point, with alarms sounding when preset thresholds are exceeded. This approach can miss:

Local gust variability along a long jib.
Interaction with crane orientation (wind hitting the broadside is more critical than aligned wind).
Forecasted conditions that could deteriorate within minutes.

Next-generation wind monitoring could include:

Multi-point sensor arrays on cranes.
Integration with Bureau of Meteorology gust forecasts.
AI models predicting when risk thresholds will be exceeded, not just reporting when they are crossed.
Automatic crane repositioning to minimise wind exposure.

This transforms alarms from reactive to predictive — the difference between warning after a hazard is present and anticipating before it materialises.

Soil Hazards: Stability Under Load

Ground conditions are another silent but critical hazard. Outriggers may impose hundreds of kilonewtons on pads, meaning even small soil weaknesses can lead to tilting or overturning.

Engineering practice already includes soil investigations: boreholes, CPT, SPT, and FEA models. But these tests capture conditions before installation, not necessarily during operation. Soil strength can change due to rainfall, groundwater shifts, or nearby excavation.

Live soil monitoring can be achieved with:

Load cells under mats to track ground reactions.
Settlement gauges to detect tilt.
Piezometers for pore pressure during rain events.
Integrated warnings when ground resistance trends downward.

This approach acknowledges soil as a living hazard that changes daily.

LiDAR and Obstacle Detection: Power Lines and Proximity Hazards

One striking feature of the Derrimut collapse was the crane’s boom striking power lines. Contact with utilities is a recurrent hazard in crane operations worldwide. While operators are trained to maintain exclusion zones, in practice visibility, fatigue, or unexpected boom movement can still lead to contact.

LiDAR scanning offers a solution.

How it works: LiDAR (Light Detection and Ranging) emits laser pulses to map surroundings in 3D with centimetre accuracy. Mounted on a crane, it can create a live digital map of nearby obstacles.
Application in cranes:
- Detecting and mapping power lines, buildings, or scaffolding in the lift path.
- Setting proximity alarms when a boom, hook, or load approaches a defined clearance.
- Combining with wind data to predict if gusts could push the load into restricted zones.

In aviation, LiDAR and radar-based systems are standard for obstacle detection. In construction, adoption is patchy. Yet the technology exists, is cost-effective, and could dramatically reduce risks of contact with hazards like live power lines.

LiDAR’s strength lies not only in static mapping but in detecting movement — for example, when a suspended load begins to swing toward a power line due to a gust. This is a quintessential developing hazard, one that static design could never fully capture.

Integrated Hazard Dashboards

Wind, soil, and LiDAR obstacle detection all provide valuable data. But their true power lies in integration. Imagine a crane operator’s cabin equipped with a single dashboard displaying:

Wind speeds and gust forecasts, colour-coded for risk.
Soil reaction forces under each outrigger, with alerts if settlement is trending.
LiDAR mapping of nearby structures and power lines, with real-time clearance zones.
Predictive risk models showing probability of instability or contact over the next 30 minutes.

This integration mirrors aviation’s cockpit: multiple inputs fused into actionable guidance. For cranes, such systems could shift the operator’s role from reactive decision-maker to proactive risk manager.

AI as a Predictive Partner

Artificial Intelligence has a natural role in hazard monitoring:

Sensor fusion: combining wind, soil, and LiDAR inputs into coherent risk profiles.
Prediction: learning from past crane incidents to forecast when risks are likely to escalate.
Decision support: providing operators with clear options (“safe to continue lift for 20 minutes” / “halt operations — clearance margin < 1m”).

The challenge is balance. AI should not replace human oversight, but augment it. Over-reliance could create new vulnerabilities if operators become complacent. The design challenge is to build AI into systems that support human judgment rather than substitute for it.

Ethics and Engineering Responsibility

The Derrimut collapse underscores the ethical responsibility of mechanical engineers. Hazard identification is not just a design requirement; it is a matter of public safety. The profession has a duty to anticipate, detect, and control risks wherever possible.

The tools now exist to monitor developing hazards — wind sensors, soil gauges, LiDAR scanners, and AI dashboards. If lives and infrastructure can be protected through wider adoption of these tools, then the question becomes one of responsibility: should they be optional, or mandatory?

Open Questions for the Future

Would integrated live monitoring have reduced the risks at Derrimut?
Should all cranes be fitted with LiDAR obstacle detection as standard?
Do we already have enough technology, but lack regulation and enforcement?
What role should AI play in balancing predictive insight with operator autonomy?

The Derrimut incident remains under investigation. No conclusions can be drawn about its specific cause until findings are published. Yet as a case study, it illustrates the broader point that hazards in crane operations are dynamic. Wind, soil, obstacles, and loads evolve minute by minute.

Mechanical engineers have the tools — wind sensors, soil monitors, LiDAR scanners, integrated dashboards, and AI — to detect these developing hazards. The challenge is to move from a culture of static design assumptions to one of continuous hazard monitoring.

The ultimate professional question is this: If aviation can integrate multiple systems to monitor and predict hazards, why can’t construction do the same for cranes? And if we can, how soon will we accept the ethical responsibility to make it standard?

References and Further Reading

ISO 4301 / AS 1418 — Crane standards covering stability and wind.
ISO 12480-1:2003 — Safe use of cranes; includes environmental hazard monitoring.
WorkSafe Victoria Guidance Notes — Crane safety management.
Holický & Retief (2017) — Probabilistic treatment of wind action in structural design.
Nguyen et al. (2020) — Real-time monitoring of crane foundation response under variable soil conditions.
Liebherr LICCON — Example of integrated load and geometry monitoring.
FAA LLWAS — Aviation’s real-time wind shear alert system, model for construction.
Recent research in LiDAR obstacle detection (e.g., IEEE Transactions on Intelligent Transportation Systems) — showing LiDAR’s potential in complex environments.

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2 August 202525 May 2026

Maximising Uptime at Transfer Points: How Hamilton By Design Optimises Chutes, Hoppers, and Conveyors for the Mining Industry

In the mining industry, system uptime isn’t just a goal—it’s a necessity. Transfer points such as chutes, hoppers, and conveyors are often the most failure-prone components in processing plants, especially in high-wear environments like HPGR (High Pressure Grinding Rolls) circuits. Abrasive ores, heavy impact, fines accumulation, and moisture can all combine to reduce flow efficiency, damage components, and drive up maintenance costs.

At Hamilton By Design, we help mining clients minimise downtime and extend the life of their material handling systems by applying advanced 3D scanning, DEM simulation, smart material selection, and modular design strategies. This ensures that transfer points operate at peak efficiency—day in, day out.

Here’s how we do it:

Optimised Flow with DEM-Based Chute & Hopper Design

Flow blockages and misaligned velocities are among the biggest contributors to transfer point failure in the mining industry. That’s why we use Discrete Element Method (DEM) simulations to model bulk material flow through chutes, hoppers, and transfer transitions.

Through DEM, we can simulate how different ores—ranging from dry coarse rock to sticky fines—move, compact, and impact structures. This allows us to tailor chute geometry, outlet angles, and flow paths in advance, helping:

Prevent material buildup or arching inside hoppers and chutes
Align material velocity with the conveyor belt speed using hood & spoon or trumpet-shaped designs
Reduce wear by managing trajectory and impact points

Optimised flow equals fewer shutdowns, longer equipment life, and better plant throughput.

Wear-Resistant Liners & Material Engineering

Not all wear is the same—and neither are the materials we use to combat it. By studying the abrasion and impact zones in your chute and hopper systems, we strategically apply wear liners suited to each application.

Our engineering team selects from:

AR (Abrasion-Resistant) steels for high-wear areas
Ceramic liners in fines-rich or ultra-abrasive streams
Rubber liners to absorb shock and reduce noise

This approach reduces liner replacement frequency, improves operational safety, and lowers the risk of unplanned shutdowns at key transfer points.

Dust and Spillage Control: Cleaner, Safer Operation

Dust and spillage around conveyors and transfer chutes can lead to extensive cleanup time, increased maintenance, and health hazards. At Hamilton By Design, we treat this as a core design challenge.

We design chutes and hoppers with:

Tight flange seals at interface points
Enclosed transitions that contain dust at the source
Controlled discharge points to reduce turbulent material drops

This reduces environmental risk and contributes to more consistent plant performance—especially in confined or enclosed processing facilities in the mining industry.

Modular & Accessible Designs for Faster Maintenance

When liners or components need replacement, every minute counts. That’s why our chute and hopper systems are built with modular sections—each engineered for fast removal and reinstallation.

Key maintenance-driven design features include:

Bolt-on panels or slide-in liner segments
Accessible inspection doors for safe visual checks
Lightweight modular components for easy handling

These details reduce labour time, enhance safety, and keep your plant online longer—especially critical in HPGR zones where throughput is non-stop.

3D laser scanner capturing a blocked mining transfer chute with a digital redesign overlay above a conveyor.

Precision 3D Scanning & 3D Modelling for Retrofit Accuracy

One of the most powerful tools we use is 3D scanning. In retrofit or brownfield projects, physical measurements can be inaccurate or outdated. We solve this by conducting detailed laser scans that generate accurate point cloud data—a precise digital twin of your plant environment.

That data is then transformed into clean 3D CAD models, which we use to:

Design retrofits that precisely match existing structure
Identify interferences or fit-up clashes before fabrication
Reduce install time by ensuring right-first-time fits

This scan-to-CAD workflow dramatically reduces rework and error margins during installation, saving time and cost during shutdown windows.

Real-World Application: HPGR & Minerals Transfer Systems

In HPGR-based circuits, transfer points between crushers, screens, and conveyors experience high rates of wear, dust generation, and blockages—particularly where moisture-rich fines are present.

Here’s how Hamilton By Design’s methodology addresses these pain points:

DEM-based flow modelling ensures the HPGR discharge flows cleanly into chutes and onto conveyors without buildup.
Hood/spoon geometries help track material to belt velocity—minimising belt wear and reducing misalignment.
Strategic liner selection extends life in critical wear zones under extreme abrasion.
Modular chute designs allow for fast liner swap-outs without major disassembly.
3D scanning & CAD design ensures new chute sections fit seamlessly into existing HPGR and conveyor frameworks.

By designing smarter transfer systems with these technologies, we enable operators to reduce downtime, increase liner life, and protect critical assets in high-throughput mining applications.

Uptime Benefits at a Glance

Performance Area	Impact on Mining Operations
Smooth bulk material flow	Fewer clogs, improved throughput, longer operating cycles
Velocity-matched discharge	Lower conveyor belt wear and downtime
Robust wear protection	Longer life, fewer liner replacements
Modular design	Faster maintenance turnarounds during scheduled shutdowns
3D scanning & CAD integration	Precise fit, reduced installation time, fewer errors during retrofit

Final Word: Engineering That Keeps the Mining Industry Moving

At Hamilton By Design, we combine mechanical engineering expertise with 3D modelling, material flow simulation, and smart fabrication practices to deliver high-performance chute, hopper, and transfer point systems tailored for the mining industry.

Whether you’re dealing with a problematic HPGR discharge, spillage issues, or planning a brownfield upgrade, our integrated design process delivers results that improve reliability, extend service life, and protect uptime where it matters most.

Looking to retrofit or upgrade transfer systems at your site?
Let’s talk. We bring together 3D scanning, DEM modelling, practical engineering, and proven reliability to deliver systems that work—from concept through to install.

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14 July 202531 May 2026

How Mechanical Engineering and Technology Are Shaping the Future of Mining in Australia

Discover how mechanical engineering, government funding, and digital innovation are driving the future of mining in Australia. Learn how Hamilton By Design leads the change.

Australia’s mining industry is undergoing one of its most significant transformations in decades. At the heart of this change lies the convergence of mechanical engineering innovation, government-backed funding, and cutting-edge technology.

With over $750 million in federal support for metals manufacturing and state-based funding for METS innovation, mechanical engineers are now in a position to redefine how mining operations are designed, maintained, and optimised.

At Hamilton By Design, we are helping clients across the country harness these changes—offering smart mechanical solutions that are efficient, resilient, and future-ready.

Key Opportunities: How Technology is Reshaping Mechanical Engineering in Mining

1. Government Funding is Fueling Innovation

In March 2025, the Australian Government announced a $750 million investment to boost advanced manufacturing and metals production in Australia.

🔗 Backing Our Metals Manufacturers – Federal Government

This funding opens doors for:

Prototyping new mechanical assemblies
Automation upgrades for existing mining plants
Local manufacturing partnerships to reduce supply chain risk

At Hamilton By Design, we are already supporting mining clients to align their capital projects with these funding pathways.

2. Digital Tools Enhance Mechanical Performance

According to the CSIRO METS Roadmap, digitalisation and automation are critical for the next phase of mining growth.

We implement:

LiDAR scanning for as-built plant modelling
Finite Element Analysis (FEA) for structural design optimisation
Predictive maintenance planning using real-time sensor data

These tools not only extend the life of critical components but also enhance safety, reduce downtime, and support remote operations.

3. WA and NSW Governments Are Supporting METS Innovation

The Western Australian government continues to support Mining Equipment, Technology and Services (METS) innovation and commercialisation through its METS Innovation Grants.

🔗 WA METS Innovation Funding

This creates opportunities for mechanical engineering firms to:

Collaborate with OEMs and fabricators
Introduce novel materials and designs for harsh mining environments
Lead the push toward zero-emissions equipment and sustainable design

Hamilton By Design’s agile project delivery and deep mechanical experience allow us to integrate seamlessly with these innovation pipelines.

The Challenges: Bridging the Gap Between Legacy and Future

Despite the exciting momentum, the sector also faces critical challenges:

Skills Gaps: Many engineers are not yet equipped with digital or automation skills.
System Complexity: Mechanical systems are increasingly integrated with electrical and digital subsystems, requiring multidisciplinary design thinking.
Capital Risk: Large investments in automation must deliver measurable value, which requires robust mechanical frameworks.

Hamilton By Design addresses these risks by offering not only high-quality design services, but also strategy, planning, and training support to ensure seamless project delivery.

Why Hamilton By Design is Your Engineering Partner of the Future

We don’t just design parts—we engineer solutions.

Our core services include:

Mining mechanical design (transfer chutes, diverter systems, sheet metal)
Structural and stress analysis (using FEA and vibration simulation)
LiDAR-enabled plant scanning for reverse engineering and documentation
Sustainable, future-ready mechanical engineering consultancy

We work with clients across NSW, WA, QLD, and SA, offering nationwide support for design, development, and delivery.

Let’s Engineer the Future Together

Mechanical engineering is no longer just about function—it’s about intelligence, adaptability, and sustainability.

At Hamilton By Design, we help mining companies, fabricators, and OEMs thrive in this new landscape. Whether you’re applying for funding, upgrading equipment, or redesigning your processing infrastructure, we have the tools, experience, and innovation to lead you forward.